U.S. patent number 10,292,875 [Application Number 14/487,115] was granted by the patent office on 2019-05-21 for absorbent articles with channels and signals.
This patent grant is currently assigned to The Procter & Gamble Company. The grantee listed for this patent is The Procter & Gamble Company. Invention is credited to Theodore Cory Fites, Sarah Ann Sanborn, John Andrew Strasemeier, Ann Cecilia Tapp, Rachael Eden Walther.
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United States Patent |
10,292,875 |
Tapp , et al. |
May 21, 2019 |
Absorbent articles with channels and signals
Abstract
An absorbent article comprising a topsheet, a backsheet, an
absorbent core comprising channels disposed between the topsheet
and the backsheet, and a printed adhesive layer disposed between
the topsheet and the absorbent core such that the printed adhesive
layer is visible through the topsheet. At least a portion of the
adhesive layer forms a pattern of one or more pairs of contoured
lines that run lengthwise in the machine direction of the absorbent
article, each pair being symmetric to its compliment across an axis
of the absorbent article drawn in the machine direction and at the
center of its width. The distance between the innermost pair of
contoured lines is from about 15 mm to about 25 mm or the amount of
adhesive comprising the printed adhesive layer is such that the
pattern coverage with the adhesive is from about 15% to about
30%.
Inventors: |
Tapp; Ann Cecilia (West
Chester, OH), Sanborn; Sarah Ann (Frankfurt, DE),
Walther; Rachael Eden (Union, KY), Fites; Theodore Cory
(Cincinnati, OH), Strasemeier; John Andrew (Aurora, IN) |
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Assignee: |
The Procter & Gamble
Company (Cincinnati, OH)
|
Family
ID: |
51626170 |
Appl.
No.: |
14/487,115 |
Filed: |
September 16, 2014 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20150080839 A1 |
Mar 19, 2015 |
|
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
61878297 |
Sep 16, 2013 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61F
13/536 (20130101); A61F 13/535 (20130101); A61F
13/512 (20130101); A61F 13/53747 (20130101); A61F
13/51394 (20130101); A61F 13/539 (20130101) |
Current International
Class: |
A61F
13/15 (20060101); A61F 13/20 (20060101); A61F
13/513 (20060101); A61F 13/537 (20060101); A61F
13/536 (20060101); A61F 13/535 (20060101); A61F
13/512 (20060101); A61F 13/539 (20060101) |
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Other References
American Chemical Society publication entitled "Contact Angle,
Wettability and Adhesion", Advances in Chemistry Series 43, Chapter
7, edited by Robert F. Gould (Copyright 1964). cited by
applicant.
|
Primary Examiner: Kidwell; Michele M
Attorney, Agent or Firm: Shipp; Wednesday G. Hagerty; Andrew
J.
Claims
What is claimed is:
1. An absorbent article comprising: a topsheet, a backsheet, an
absorbent core disposed between the topsheet and the backsheet, and
a printed adhesive layer comprising an adhesive and being disposed
between the topsheet and the absorbent core; wherein the absorbent
core comprises absorbent material and channels, wherein said
channels are substantially free of absorbent material; wherein the
printed adhesive layer is visible through the topsheet and
comprises an adhesive pattern coverage of 15% to 30%; wherein at
least a portion of the adhesive layer forms a pattern of one or
more pairs of contoured lines that run lengthwise in the machine
direction of the absorbent article, each pair comprising contoured
lines that are symmetric and each concave with respect to an axis
of the absorbent article drawn in the machine direction and at the
center of its width; wherein another portion of the printed
adhesive layer comprises a printed underlay; and wherein an
innermost pair of contoured lines is separated by a lateral
distance of 15 mm to 25 mm; wherein the absorbent core channels are
contoured; and wherein the printed adhesive layer substantially
matches the contour of the absorbent core channels and wherein the
absorbent core channels are symmetric and mirror images of one
another with respect to the axis of the absorbent article drawn in
the machine direction and at the center of its width.
2. The absorbent article of claim 1, further comprising an
acquisition layer disposed between the topsheet and the absorbent
core, wherein the printed adhesive layer is printed onto the
acquisition layer.
3. The absorbent article of claim 2, wherein the printed adhesive
layer is a different color than that of the acquisition layer.
4. The absorbent article of claim 3, wherein the acquisition layer
has a surface that is adjacent to the absorbent core, and the
printed adhesive layer is printed onto the surface of the
acquisition layer that is adjacent to the absorbent core.
5. The absorbent article of claim 1, wherein the absorbent article
further comprises graphics printed on the backsheet.
6. The absorbent article of claim 5, wherein the graphics printed
on the backsheet substantially match the pattern of the printed
adhesive layer.
7. The absorbent article of claim 1, wherein the topsheet comprises
embossing.
8. The absorbent article of claim 1, wherein the channels and the
pattern of the printed adhesive layer do not overlap.
9. An absorbent article comprising: a topsheet, a backsheet, an
absorbent core disposed between the topsheet and the backsheet, and
a printed adhesive layer comprising an adhesive and being disposed
between the topsheet and the absorbent core; wherein the absorbent
core comprises an absorbent layer having absorbent material and
channels, wherein the channels are substantially free of absorbent
material; wherein the printed adhesive layer is visible through the
topsheet and comprises an adhesive pattern coverage of 15% to 30%;
wherein the absorbent layer comprises an average length and is
delimited by two transverse edges and two longitudinal edges;
wherein the absorbent core channels are contoured and do not extend
to any of the transverse edges such that each channel is separated
from each transverse edge by a minimum distance that is at least 5%
of the average length of the absorbent layer; and wherein the
printed adhesive layer comprises a pattern that substantially
matches the contour of the absorbent core channels.
Description
FIELD OF THE INVENTION
The present invention relates to absorbent articles with channeled
cores and printed signals.
BACKGROUND OF THE INVENTION
Absorbent articles for receiving and retaining bodily discharges
such as urine or feces are well known in the art. Examples of these
include disposable diapers, training pants and adult incontinence
articles. Typically, disposable diapers comprise a liquid pervious
topsheet that faces the wearer's body, a liquid impervious
backsheet that faces the wearer's clothing and an absorbent core
interposed between the liquid pervious topsheet and the
backsheet.
An important component of disposable absorbent articles is the
absorbent core/absorbent structure. The absorbent core/structure
typically includes superabsorbent polymer material, such as
hydrogel-forming polymer material, also referred to as absorbent
gelling material, AGM, or superabsorbent polymer, SAP. This
superabsorbent polymer material ensures that large amounts of
bodily fluids, e.g. urine, can be absorbed by the absorbent article
during its use and be locked away, thus providing low rewet and
good skin dryness.
Traditionally, the superabsorbent polymer material is incorporated
into the absorbent core structure with pulp, i.e. cellulose fibers.
To make the absorbent core structures thinner, it has been proposed
to reduce or eliminate these cellulose fibers from the absorbent
core structures.
However, it was found that some absorbent core structures with
reduced cellulose fiber levels, while very thin when not loaded
with bodily fluids, may have an increased stiffness when partially
loaded or fully loaded, especially in those regions which comprise
most of the absorbent capacity of the absorbent article, such as
the front region and crotch region of the diaper. It has been found
that by providing specific permanent channels that are free of
superabsorbent polymer particles or free of superabsorbent polymer
material, improved liquid transport is achieved, and hence faster
acquisition, and more efficient liquid absorbency over the whole
absorbent structure; even though less absorbent material may be
used, improved performance can be achieved. By immobilizing the
absorbent material or channels, by the use of adhesive, the
channels are more permanent, and remain channels during the use of
the absorbent structure, e.g. when friction is applied to the
absorbent structure, or when the absorbent structure is wetted, and
the absorbent material expands. Furthermore, it has been found that
by the provision of such channels, for example in the front region
of the absorbent core/structure, and/or in the crotch region of the
absorbent core/structure, a diaper of increased flexibility can be
provided, while maintaining its performance throughout its use.
As the functionality of the absorbent core is changed to improve,
e.g. absorbency, fit, or reduced cost, the process capability
and/or performance and/or appearance of the article may be affected
negatively. Efforts can be made to modify the article or parts of
the article in order to provide them with a particular appearance.
In some examples, the article may be modified to communicate or
signal to the caregiver that the channels exist in the absorbent
core of the article, and that the channels are there to create
faster and more efficient liquid absorbency. Such signalling or
communication may be done, for example, via exterior graphics
and/or interior printed adhesives.
Due to the intersection of process capability, technical product
performance, and successful consumer communication it is important
to understand the interaction of these three components to design
the right balanced product design. While running the process in a
way that best meets consumer communication it can cause negative
impacts to the technical performance of the product. While running
the best consumer communication design and the right technical
product design could result in a process that is not capable of
ongoing production. An optimized process and product design
combination may not deliver the optimum in consumer communication.
As such, there is a need for improved absorbent articles comprising
absorbent cores with channels that exhibit excellent process
capability, technical product performance, and have a successful
consumer communication.
SUMMARY OF THE INVENTION
The present invention is directed to an absorbent article
comprising a topsheet, a backsheet, an absorbent core comprising
channels disposed between the topsheet and the backsheet, and a
printed adhesive layer disposed between the topsheet and the
absorbent core such that the printed adhesive layer is visible
through the topsheet. At least a portion of the adhesive layer
forms a pattern of one or more pairs of contoured lines that run
lengthwise in the machine direction of the absorbent article, each
pair being symmetric to its compliment across an axis of the
absorbent article drawn in the machine direction and at the center
of its width. The distance between the innermost pair of contoured
lines is from about 15 mm to about 25 mm or the amount of adhesive
comprising the printed adhesive layer is such that the pattern
coverage with the adhesive is from about 15% to about 30%.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plan view of a diaper in accordance with one
non-limiting embodiment.
FIG. 2 shows a perspective view of an absorbent structure in
accordance with one non-limiting embodiment.
FIG. 3 shows a cross sectional view of an absorbent core in
accordance with one non-limiting embodiment.
FIGS. 4a and 4b show top view representations of non-limiting
embodiments of printed adhesive patterns.
FIGS. 5a and 5b show top view representations of non-limiting
embodiments of printed adhesive patterns.
FIGS. 6a and 6b show top view representations of non-limiting
embodiments of printed adhesive patterns of the present
invention.
FIGS. 7a and 7b show top view representations of non-limiting
embodiments of printed adhesive patterns.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
"Absorbent article" refers to a device that absorbs and contains
body exudates, and, more specifically, refers to devices that are
placed against or in proximity to the body of the wearer to absorb
and contain the various exudates discharged from the body.
Absorbent articles may include adult and infant diaper, including
pants, such as infant training pants and adult incontinence
undergarments, and feminine hygiene products, such as sanitary
napkins and panty-liners and adult in continent pads, and breast
pads, care mats, bibs, wound dressing products, and the like.
Absorbent articles may further include floor cleaning articles,
food industry articles, and the like. As used herein, the term
"body fluids" or "body exudates" includes, but is not limited to,
urine, blood, vaginal discharges, breast milk, sweat and fecal
matter.
As used herein "diaper" refers to devices which are intended to be
placed against the skin of a wearer to absorb and contain the
various exudates discharged from the body. Diapers are generally
worn by infants and incontinent persons about the lower torso so as
to encircle the waist and legs of the wearer. Examples of diapers
include infant or adult diapers and pant-like diapers such as
training pants. "Training pant", as used herein, refers to
disposable garments having a waist opening and leg openings
designed for infant or adult wearers. A pant may be placed in
position on the wearer by inserting the wearer's legs into the leg
openings and sliding the pant into position about a wearer's lower
torso. A pant may be pre-formed by any suitable technique
including, but not limited to, joining together portions of the
article using refastenable and/or non-refastenable bonds (e.g.,
seam, weld, adhesive, cohesive bond, fastener, etc.). A pant may be
pre-formed anywhere along the circumference of the article (e.g.,
side fastened, front waist fastened).
"Disposable" is used herein to describe articles that are generally
not intended to be laundered or otherwise restored or reused (i.e.,
they are intended to be discarded after a single use and, may be
recycled, composted or otherwise disposed of in an environmentally
compatible manner). As used herein "absorbent structure" refers to
a three dimensional structure useful to absorb and contain liquids,
such as urine. The absorbent structure may be the absorbent
structure of an absorbent article or may be only part of the
absorbent core of an absorbent article, i.e. an absorbent component
of the absorbent core, as will be further described herein.
"Superabsorbent polymer material" as used herein refers to
substantially water-insoluble polymer material that can absorb at
least 10 times (and typically at least 15 times or at least 20
times) its weight of a 0.9% saline solution in de-mineralized water
as measured using the Centrifuge Retention Capacity test (Edana
441.2-01).
"Nonwoven material" as used herein refers to a manufactured web of
directionally or randomly orientated fibers, excluding paper and
products which are woven, knitted, tufted, stitch-bonded
incorporating binding yarns or filaments, or felted by wet-milling,
whether or not additionally needled. Nonwoven materials and
processes for making them are known in the art. Generally,
processes for making nonwoven materials comprise laying fibers onto
a forming surface, which may comprise spunlaying, meltblowing,
carding, airlaying, wetlaying, coform and combinations thereof. The
fibers may be of natural or man-made origin and may be staple
fibers or continuous filaments or be formed in situ.
"Visible" as used herein means capable of being perceived by the
unaided human eye.
The present invention provides absorbent articles with absorbent
cores comprising channels and printed signals that communicate the
channels, such as those disclosed in U.S. Ser. No. 14/077,355 filed
on 12 Nov. 2013. Further, the present invention provides absorbent
articles with absorbent cores comprising channels and printed
signals that communicate the channels. The present invention
relates to absorbent articles with channels disclosed in U.S.
application Ser. Nos. 13/491,642, 13/491,643, 13/491,644, and
13/491,648, all filed Jun. 10, 2011.
The absorbent structure (13) herein comprises a supporting sheet
(16) with an absorbent layer (17) of absorbent material (50). The
absorbent material (50) comprises at least a superabsorbent polymer
material and optionally a cellulosic material, such as a cellulose,
e.g. pulp, or modified cellulose.
The absorbent structure (13) also comprises one or more adhesive
materials, further described below. The absorbent layer (17) is
three dimensional and comprises a first substantially longitudinal
channel (26) and a second substantially longitudinal channel (26)
that are substantially free of said superabsorbent polymer
material. Other materials may be present in said channels (26), as
further described below, for example said one or more adhesive
materials (40; 60).
The absorbent structure (13) and the absorbent layer (17) each have
a longitudinal dimension and average length L, e.g. extending in
the longitudinal dimension of the structure or layer and a
transverse dimension and average width W, e.g. extending in the
transverse dimension of the structure or layer. The absorbent
structure (13) and the absorbent layer (17) each have a front
region, being in use towards the front of the user, back region,
being in use towards the back of the user, and therein between a
crotch region, each extending the full transverse width of the
structure/layer, and each having 1/3 of the average length of the
structure/layer.
The absorbent structure (13) and the absorbent layer (17) each
possess a central longitudinal axis X, a central transverse axis Y
perpendicular to said central longitudinal axis X; said absorbent
layer (17) and said absorbent structure (13) have each a pair of
opposing longitudinal side edges extending in the longitudinal
dimension of the structure or layer and a pair of opposing
transverse edges (19), e.g. front transverse edge being in use
towards the front of a user (wearer), and a back transverse edge
being in use towards the back of a user. The longitudinal side
edges (18) and/or transverse edges (19) of the absorbent structure
(13) or absorbent layer (17) may be parallel respectively to the
central longitudinal axis and/or central transverse axis
respectively or one or more may be curvilinear, and for instance
provide for a narrower transverse dimension in the crotch region.
Typically the longitudinal side edges are mirror images of one
another in the longitudinal X-axis.
The central longitudinal X-axis of the absorbent layer (17)
delimits first and second longitudinal side portions (20) of the
absorbent layer (17), respectively, referred herein as longitudinal
side portions (20). Each of said longitudinal side portions is thus
present in said front region, crotch region and back region, and
hence, there is a first longitudinal portion's front region, and a
second longitudinal portion's front region etc. In some embodiments
herein, said longitudinal portions of the absorbent layer (17) are
mirror images of one another in the X-axis of the layer.
The absorbent layer (17) comprises at least a first channel (26)
and second channel (26) that are substantially free of (e.g. free
of) said superabsorbent polymer particles, said channels (26)
extending through the thickness (height) of the absorbent layer
(17). It should be understood that, accidentally, a small,
negligible amount of superabsorbent polymer particles may be
present in the channel, which does not contribute to the overall
functionality. When the absorbent layer (17) comprises cellulosic
or cellulose, in some embodiments the said first and second
channels (26) are also free of such cellulosic/cellulose
material.
The first channel (26) is present in said first longitudinal side
portion of the absorbent layer (17) and the second channel (26) is
present in said second longitudinal side portion of the absorbent
layer (17).
The first and second channel (26) each extend substantially
longitudinally, which means typically that each channel (26)
extends more in the longitudinal dimension than in the transverse
dimension, and typically at least twice as much in the longitudinal
dimension than in the transverse dimension.
Thus, this includes channels (26) that are completely longitudinal
and parallel to the longitudinal direction of said absorbent layer
(17) (i.e. paralleled to said longitudinal-axis); and this includes
channels (26) that may be curved, provided the radius of curvature
is typically at least equal (optionally at least 1.5 or at least
2.0 times this average transverse dimension) to the average
transverse dimension of the absorbent layer; and this includes
channels (26) that are straight but under an angle of (e.g. from
5.degree.) up to 30.degree., or for example up to 20.degree., or up
to 10.degree. with a line parallel to the longitudinal axis. This
may also include channels with an angle therein, provided said
angle between two parts of a channel is at least 120.degree., at
least 150.degree.; and in any of these cases, provided the
longitudinal extension of the channel is more than the transverse
extension.
In some embodiments, there may be no completely or substantially
transverse channels present in at least said crotch region, or no
such channels at all.
Each of said first and second channels (26) may have an average
width W' that is least 4% of the average width W of said absorbent
layer (17), or for example W' is at least 7% of W; and/or for
example and up to 25% of W, or up to 15% of W; and/or for example
at least 5 mm; and for example up to 25 mm, or for example up to 15
mm.
Each of said first and second channels (26) may have an average
length L' which may for example be up to 80% of the average length
L of said absorbent layer (17); if the channels (26) are only in
the front region, or only in the crotch region, or only in the back
region, L' is for example up to 25% of L, or up to 20% of L, and/or
L' is for example at least 5% of L, or at least 10% of L; and/or L'
is for example at least 10 mm, or at least 20 mm; if the channels
(26) extend in said crotch region and front region, and optionally
the back region, L' is for example up to 80% of L, or up to 70% of
L, and/or L' is for example at least 40% of L, or at least 50% of
L. In case the channel is not parallel to the longitudinal axis,
the length L' of the channel is the length as measured by
projection against the longitudinal axis.
The channels (26) may typically be so-called "permanent" channels
(26). By permanent, it is meant that the integrity of the channels
(26) is at least partially maintained both in the dry state and in
the wet state, including during friction by the wearer thereon.
Permanent channels (26) may be obtained by provision of one or more
adhesive material that immobilize said absorbent material (50),
and/or said channels (26), e.g. or said absorbent layer (17),
and/or that immobilize said supporting sheet (16) into said
channels (26), or part thereof. The absorbent cores (7) may
comprise in particular permanent channels formed by bonding of the
first supporting sheet (16) and second supporting sheet (16')
through the channels. Typically, glue may be used to bond both
supporting sheets throught the channel, but it is possible to bond
via other known means, for example ultrasonic bonding, or heat
bonding. The supporting layers can be continuously bonded or
intermittently bonded along the channels.
Indeed, the inventors observed that such channels provide for fast
liquid acquisition which reduces risk of leakages. The permanent
channels help to avoid saturation of the absorbent layer in the
region of fluid discharge (such saturation increases the risk of
leakages). Furthermore, in contrast to what would be expected,
while decreasing the overall amount of superabsorbent polymer
material in the absorbent structure is reduced (by providing
channels free of such material), the fluid handling properties of
the absorbent structure, or diaper, are improved. Permanent
channels, also have the further advantages that in wet state the
absorbent material cannot move within the core and remains in its
intended position, thus providing better fit and fluid
absorption.
As for example shown in FIG. 3, one or more adhesive materials (60)
may be present between said supporting sheet (16) and said
absorbent layer (17), or parts thereof (e.g. herein referred to as,
"second adhesive material"). For example, an adhesive material is
applied to portions of said supporting sheet (16) that are to
coincide with the channels (26), so that in said channels the
supporting sheet can be bonded with said adhesive to the walls of
the channel, or part thereof or to a further material, as described
herein; and/or the adhesive may be applied to portions of the
supporting sheet (16) that are to coincide with the absorbent
material (50), to immobilize said material and avoid extensive
migration thereof into said channels; the adhesive may be applied
over substantially the whole surface area of the supporting sheet
(16), e.g. substantially continuously and/or homogeneously. This
may for example be a hotmelt adhesive applied by printing, slot
coating or spraying.
In addition, or alternatively, the absorbent structure (13) may
comprise one or more adhesive materials (40) applied on said
absorbent layer (17) or part thereof, that is already supported by
said supporting sheet (16), (herein referred to as "first adhesive
material") e.g. after said absorbent material (50) is combined
with/deposited on said supporting sheet (16) to form an absorbent
layer (17). This may for example be a thermoplastic fibrous
adhesive, as described herein after. It some embodiments, this may
be applied continuously over the absorbent layer (17), hence over
the absorbent material (50) and in the channels (26), to immobilize
the absorbent layer and to optionally also adhere the supporting
sheet in said channel, as described above. This is for example
shown in FIG. 3.
It should be understood that the first and second adhesive material
may be the same type of adhesive, for example as a thermoplastic
hotmelt adhesive, for example as described below, the difference
between the first and second adhesive thus being the location where
it is applied.
In some embodiments, said one or more adhesive material are at
least present in the channels (26), for example at least said first
adhesive material, or both said first and second adhesive material.
It may thus be present on the longitudinal walls of the channels
(26) (extending the height of the absorbent layer (17) and the
length thereof). If the supporting sheet (16) material folds into
said channels (26), or part thereof, e.g. the supporting sheet (16)
has undulations into said channels (26) or part thereof, said
undulations may be fixed to said walls or part thereof, to ensure
the channels (26) are maintained (at least partially) during
use.
The first and second channels (26) may be mirror images of one
another with respect to the central longitudinal axis (X-axis) of
the absorbent layer (17)/structure.
In some embodiments, there is no channel (26) that coincides with
said longitudinal axis of said absorbent layer (17). The channels
(26) may be spaced apart from one another over their whole
longitudinal dimension. The smallest spacing distance D (the
distance between the innermost pair of the contoured lines) may for
example be at least 5% of average transverse dimension W of layer,
or for example at least 10% of W, or at least 15% of W.
Furthermore, in order to reduce the risk of fluid leakages, the
longitudinal main channels (26) typically do not extend up to any
of the transverse edges (19) and/or longitudinal edges (18) of the
absorbent layer (17). Typically, the smallest distance I' between a
channel (26) and the nearest longitudinal edge corresponds to at
least 5% of W, or for example to at least 10% of W. In some
embodiments, the distance is for example at least 10 mm; the
smallest distance between a channel and the nearest transverse edge
(19) of the absorbent layer (17) may for example be at least 5% of
the average length L of the layer.
The absorbent structure may comprise only two channels, for example
only in the front region, or for example in the central (crotch)
region, and optionally extending into the front and/or back region,
such as shown FIG. 2.
The absorbent structure (13) may comprise more than two of such
channels (26), for example at least 4, or at least 5 or at least 6.
Some or all of these may be substantially parallel to one another,
for example being all straight and completely longitudinally,
and/or two or more or all may be mirror images of one another in
the longitudinal axis, or two or more may be curved or angled and
fore example mirror images of one another in the longitudinal axis,
and two or more may be differently curved or straight, and for
example mirror images of one another in the longitudinal axis.
For example the front region of the absorbent layer (17) may
comprise two or more channels (26), that are typically mirror
images of one another in the longitudinal axis of the layer, and
the crotch region may comprise two or more channels (26), that are
typically mirror images of one another in the longitudinal axis of
the layer, and the latter may optionally extend into the front
region and/or back region, with any of applicable dimensions and
other characteristics described above. Optionally, further channels
may be present in the back region.
The first and second channels (26), and optionally further channels
(26), may be positioned in said absorbent layer (17) such that
there is a central longitudinal strip, coinciding with said
longitudinal axis, which is free of any channels (26); said
absorbent material (50) may be substantially continuously present
in said strip. For example, said strip may have a minimum width D
(the distance between the innermost pair of the contoured lines) of
at least 5% of W, or at least 10% of W.
In some embodiments, in said central longitudinal strip between two
neighboring channels (26) the average basis weight of absorbent
material (50), or of said superabsorbent polymer material, is at
least 350, and for example up to 1000 grams per m.sup.2, or for
example from 450 grams per m.sup.2, and for example up to 750 grams
per m.sup.2.
In some embodiments, adjacent each first and second channel, and
optionally adjacent said further channels, said absorbent material
(50) is substantially continuously present.
The absorbent structure (13) typically comprises one or more
further materials (e.g. a further material layer) to cover the
absorbent layer (17), herein referred to as further material; the
further material may be a layer comprising adhesive, for example on
the surface that is to contact the absorbent layer (17) of the
absorbent structure (13) herein. Thus, the further material may
comprise, on the surface to be placed adjacent said absorbent layer
(17) of the absorbent structure (13), an adhesive material.
The resulting structure is herein referred to as "absorbent core
(7)". An example thereof is shown in FIG. 3.
This further material may be a further absorbent structure, with a
second absorbent layer (17') and a second supporting sheet (16'),
so that both absorbent layers (17, 17') are sandwiched between said
supporting sheets (16; 16'); this may be a further absorbent
structure of the disclosure, with two or more channels (26') as
described herein, and for example shown in FIG. 3; or this may be
an absorbent structure as described herein but without channels;
and/or it may be an absorbent structure as described herein but
without adhesive.
The second absorbent structure may be identical to the first
absorbent structure (13), or they may both be absorbent structure
with channels (26; 26') of the disclosure, but they may be
different, for example having different channels, different number
of channels, different adhesive, different adhesive application or
combinations thereof.
The channels (26), or some of those, of the first absorbent
structure (13) and the channels (26') of the second absorbent
structure, or some of those, may coincide and overlap with one
another; e.g. completely or for example coincide only partially and
overlap only partially; or some or all of the channels (26; 26')
may even not coincide and not overlap one another. In some
embodiments they are about identical to one another and the
channels (26) of one structure substantially completely coincide
and overlap the channels (26) of another structure.
In some embodiments, the further material may be a part of the
supporting sheet (16), which is folded over the absorbent layer
(17) and then sealed along the peripheral edges, to enclose the
absorbent layer (17).
In some embodiments, the further material is a further supporting
sheet (16'), i.e. the absorbent structure (13) is covered with a
further supporting sheet (16'), said absorbent layer then being
sandwiched between the two supporting sheets.
In some embodiments, the further material may be an acquisition
material layer and/or an acquisition sheet, for example sealed to
said supporting sheet (16). In some embodiments, the further
material includes a further absorbent structure, e.g. any of those
described above, or further supporting sheet (16'), and then
combined with an acquisition material layer, and optionally a
further acquisition sheet.
The further material may also be an acquisition material layer
present adjacent said absorbent layer (17), the acquisition
material layer optionally comprising chemically cross-linked
cellulosic fibers, and the acquisition material layer being
supported on a second supporting sheet (16'). The absorbent layer
(17) and the acquisition material layer may then be sandwiched
between said supporting sheet (16) of the first structure and said
second supporting sheet (16'). The acquisition material layer may
also further comprise channels (26'), in particular substantially
completely overlapping with the channels (26) of said first
absorbent structure (13).
The supporting sheet (16) of the first structure and/or the second
supporting sheet (16') of the acquisition material layer may fold
into the channels (26) of the first absorbent structure (13) and/or
optionally into the channels (26') of the acquisition material
layer, if present, or part of these channels (26, 26'). The one or
more adhesive materials may be at least present in the channels
(26, 26'), or part thereof, and the supporting sheets (16, 16') may
be adhered to one another in said channels (26, 26') by one or more
of these adhesive materials. Another second adhesive (60') may be
present between the second supporting sheet (16') and the
acquisition material layer. Another adhesive may be placed between
the acquisition material layer and the absorbent layer (17), in
addition to the thermoplastic adhesive (40), to improve better
adhesion of both layers.
In any of these cases, the further material can then be sealed to
the supporting sheet (16) along the peripheral edges thereof, to
enclose the absorbent layers (17; optionally 17').
In any of these cases the supporting sheet (16) or acquisition
layer/sheet may fold into (i.e. undulate into) said channels (26)
or part thereof. It may be adhered to the supporting sheet (16) of
the absorbent structure (13) of the disclosure in said channels
(26), e.g. by an adhesive material, as described herein.
Alternatively, or in addition, it may be adhered to the walls of
the channels (26 and/or 26') or part thereof.
In some embodiments the absorbent structure (13) comprises such a
further material overlaying said absorbent layer (17), and a
pressure means is applied selectively to said supporting sheet (16)
and/or to said further material, in those parts that coincide with
said channels (26 and/or 26'), to pressurize said supporting sheet
(16) and/or said further material into said channels of the
absorbent structure (13) and/or into the channels of a further
(second) absorbent structure if present (into channels 26 and/or
26', if present), to aid formulation of said undulations and/or to
aid adhering of the further material and said supporting sheet (16)
to one another in said channels (26 and/or 26'), if an adhesive
material is present as described herein.
The pressure means may be a pressure roll with raised portions that
have substantially the size, shape, pattern of said channels (26
and/or 26'), that can coincide (i.e.: mate) with said parts of the
supporting sheet (16) or further material coinciding with said
channels (26 and/or 26').
In some embodiments, the further (e.g. second) supporting sheet
(16') may be wider than the absorbent structure to enable the
second supporting sheet (16') to fold into the channels (26 and/or
26') or part thereof, and thereby may adhere to the first
supporting sheet (16).
In embodiments wherein the absorbent core (7) comprises two (or
more) absorbent structures comprising the channels (26; 26'),
described herein, it may be that one or two, or more, or all, of
the channels (26) of one absorbent structure (13) substantially
superpose the channels (26') of the adjacent absorbent structure.
The resulting absorbent core (7) is then a laminate of absorbent
structures with channels (26; 26'), wherein the channels (26; 26')
extend substantially through the thickness of the absorbent layers
(17;17').
In addition or alternatively, it may be that one or two, or more,
or all, channels (26) of one absorbent structure (13) do not
superpose the channels (26') of the adjacent absorbent structure;
they may for example be complementary with the channels (26) of the
adjacent structure. By complementary it is meant that the channels
(26') of the second absorbent structure form an extension of the
channels (26) of the first absorbent structure (13).
In some embodiments, the absorbent core (7) may comprise two or
more absorbent structures (13), one of which being the structure of
the disclosure, and one being an absorbent structure (13) with a
supporting sheet (16') with thereon an absorbent layer (17') (with
superabsorbent polymer material) without channels and/or without
adhesive.
If a second absorbent structure is present in the absorbent core
(7), this may comprise one or more adhesives, in the manner as
described above, and for the reasons described above.
For example, it may be present such that it coincides with the
channels (26) of the first absorbent structure (13) at least,
and/or with its channels (26'), if present.
The absorbent layer (17) comprises absorbent material (50) that
comprises superabsorbent polymer material (e.g. particles),
optionally combined with cellulosic material (including for example
cellulose, comminuted wood pulp in the form of fibers). The further
material described above (e.g. a further, second absorbent
structure may include an absorbent material, and the following may
apply thereto too).
In some embodiment, the absorbent material (50) may comprise at
least 60%, or at least 70% by weight of superabsorbent polymer
material, and at the most 40% or at the most 30% of cellulosic
material.
In some other embodiments, the absorbent layer (17) comprises
absorbent material (50) that consists substantially of absorbent
polymer material, e.g. particles, e.g. less than 5% by weight (of
the absorbent material (50)) of cellulosic material is present; and
said absorbent layer (17)/absorbent structure (13), may be free of
cellulosic material.
Typically, the superabsorbent polymer material is in the form of
particles. Suitable for use in the absorbent layer (17) can
comprise any superabsorbent polymer particles known from
superabsorbent literature, for example such as described in Modern
Superabsorbent Polymer Technology, F. L. Buchholz, A. T. Graham,
Wiley 1998. The absorbent polymer particles may be spherical,
spherical-like or irregular shaped particles, such as
Vienna-sausage shaped particles, or ellipsoid shaped particles of
the kind typically obtained from inverse phase suspension
polymerizations. The particles can also be optionally agglomerated
at least to some extent to form larger irregular particles.
In some embodiments herein, the absorbent material (50) as a whole
and/or said particulate superabsorbent polymer material at least,
has a high sorption capacity, e.g. having a CRC of for example at
least 20 g/g, or at 30 g/g. Upper limits may for example be up to
150 g/g, or up to 100 g/g.
In some embodiments herein, the absorbent material (50) comprising
or consisting of superabsorbent polymer particles that are formed
from polyacrylic acid polymers/polyacrylate polymers, for example
having a neutralization degree of from 60% to 90%, or about 75%,
having for example sodium counter ions.
The superabsorbent polymer may be polyacrylates and polyacrylic
acid polymers that are internally and/or surface cross-linked.
Suitable materials are described in the PCT Patent Application WO
07/047598 or for example WO 07/046052 or for example WO2009/155265
and WO2009/155264. In some embodiments, suitable superabsorbent
polymer particles may be obtained by current state of the art
production processes as is more particularly described in WO
2006/083584. The superabsorbent polymers may be internally
cross-linked, i.e. the polymerization is carried out in the
presence of compounds having two or more polymerizable groups which
can be free-radically copolymerized into the polymer network.
Useful crosslinkers include for example ethylene glycol
dimethacrylate, diethylene glycol diacrylate, allyl methacrylate,
trimethylolpropane triacrylate, triallylamine, tetraallyloxyethane
as described in EP-A 530 438, di- and triacrylates as described in
EP-A 547 847, EP-A 559 476, EP-A 632 068, WO 93/21237, WO
03/104299, WO 03/104300, WO 03/104301 and in DE-A 103 31 450, mixed
acrylates which, as well as acrylate groups, include further
ethylenically unsaturated groups, as described in DE-A 103 31 456
and DE-A 103 55 401, or crosslinker mixtures as described for
example in DE-A 195 43 368, DE-A 196 46 484, WO 90/15830 and WO
02/32962 as well as cross-linkers described in WO2009/155265. The
superabsorbent polymer particles may be externally surface
cross-linked, or post cross-linked. Useful post-crosslinkers
include compounds including two or more groups capable of forming
covalent bonds with the carboxylate groups of the polymers. Useful
compounds include for example alkoxysilyl compounds,
polyaziridines, polyamines, polyamidoamines, di- or polyglycidyl
compounds as described in EP-A 083 022, EP-A 543 303 and EP-A 937
736, polyhydric alcohols as described in DE-C 33 14 019, cyclic
carbonates as described in DE-A 40 20 780, 2-oxazolidone and its
derivatives, such as N-(2-hydroxyethyl)-2-oxazolidone as described
in DE-A 198 07 502, bis- and poly-2-oxazolidones as described in
DE-A 198 07 992, 2-oxotetrahydro-1,3-oxazine and its derivatives as
described in DE-A 198 54 573, N-acyl-2-oxazolidones as described in
DE-A 198 54 574, cyclic ureas as described in DE-A 102 04 937,
bicyclic amide acetals as described in DE-A 103 34 584, oxetane and
cyclic ureas as described in EP-A 1 199 327 and
morpholine-2,3-dione and its derivatives as described in WO
03/031482.
The superabsorbent polymers or particles thereof may have surface
modifications, such as being coated or partially coated with a
coating agent. Examples of coated absorbent polymer particles are
disclosed in WO2009/155265. The coating agent may be such that it
renders the absorbent polymer particles more hydrophilic. For
example, it may be hydrophilic (i.e. fumed) silica, such as
Aerosils. The coating agent may be a polymer, such as an elastic
polymer or a film-forming polymer or an elastic film-forming
polymer, which forms an elastomeric (elastic) film coating on the
particle. The coating may be a homogeneous and/or uniform coating
on the surface of the absorbent polymer particles. The coating
agent may be applied at a level of from 0.1% to 5%.
The superabsorbent polymer particles may have a particle sizes in
the range from 45 .mu.m to 4000 .mu.m, more specifically a particle
size distribution within the range of from 45 .mu.m to about 2000
.mu.m, or from about 100 .mu.m to about 1000 or to 850 .mu.m. The
particle size distribution of a material in particulate form can be
determined as it is known in the art, for example by means of dry
sieve analysis (EDANA 420.02 "Particle Size distribution).
In some embodiments herein, the superabsorbent material is in the
form of particles with a mass medium particle size up to 2 mm, or
between 50 microns and 2 mm or to 1 mm, or from 100 or 200 or 300
or 400 or 500 .mu.m, or to 1000 or to 800 or to 700 .mu.m; as can
for example be measured by the method set out in for example
EP-A-0691133. In some embodiments of the disclosure, the
superabsorbent polymer material is in the form of particles whereof
at least 80% by weight are particles of a size between 50 .mu.m and
1200 .mu.m and having a mass median particle size between any of
the range combinations above. In addition, or in another embodiment
of the disclosure, said particles are essentially spherical. In yet
another or additional embodiment of the disclosure the
superabsorbent polymer material has a relatively narrow range of
particle sizes, e.g. with the majority (e.g. at least 80%, at least
90% or even at least 95% by weight) of particles having a particle
size between 50 .mu.m and 1000 .mu.m, between 100 .mu.m and 800
.mu.m, between 200 .mu.m and 600 .mu.m.
The absorbent structure (13) herein comprises a supporting sheet
(16) on which said absorbent material (50) is supported and
immobilized. The further material may be or include a supporting
sheet (16'), and the following applies also to such a sheet
(16').
This supporting sheet (16) may be an individual sheet or a web
material that is subsequently divided into individual absorbent
structures (13), in particular paper, films, wovens or nonwovens,
or laminate of any of these.
In some embodiments herein, the supporting sheet (16) is a
nonwoven, e.g. a nonwoven web, such as a carded nonwoven, spunbond
nonwoven or meltblown nonwoven, and including nonwoven laminates of
any of these.
The fibers may be of natural or man-made origin and may be staple
or continuous filaments or be formed in situ. Commercially
available fibers have diameters ranging typically from less than
about 0.001 mm to more than about 0.2 mm and they come in several
different forms: short fibers (known as staple, or chopped),
continuous single fibers (filaments or monofilaments), untwisted
bundles of continuous filaments (tow), and twisted bundles of
continuous filaments (yarn). The fibers may be bicomponent fibers,
for example having a sheath-core arrangement, e.g. with different
polymers forming the sheath and the core. Nonwoven fabrics can be
formed by many processes such as meltblowing, spunbonding, solvent
spinning, electrospinning, and carding. The basis weight of
nonwoven fabrics is usually expressed in grams per square meter
(gsm).
The nonwoven herein may be made of hydrophilic fibers;
"Hydrophilic" describes fibers or surfaces of fibers, which are
wettable by aqueous fluids (e.g. aqueous body fluids) deposited on
these fibers. Hydrophilicity and wettability are typically defined
in terms of contact angle and the strike through time of the
fluids, for example through a nonwoven fabric. This is discussed in
detail in the American Chemical Society publication entitled
"Contact angle, wettability and adhesion", edited by Robert F.
Gould (Copyright 1964). A fiber or surface of a fiber is said to be
wetted by a fluid (i.e. hydrophilic) when either the contact angle
between the fluid and the fiber, or its surface, is less than
90.degree., or when the fluid tends to spread spontaneously across
the surface of the fiber, both conditions are normally co-existing.
Conversely, a fiber or surface of the fiber is considered to be
hydrophobic if the contact angle is greater than 90.degree. and the
fluid does not spread spontaneously across the surface of the
fiber.
The supporting sheet (16) herein may be air-permeable. Films useful
herein may therefore comprise micro pores. Nonwovens herein may for
example be air permeable. The supporting sheet (16) may have for
example an air-permeability of from 40 or from 50, to 300 or to 200
m.sup.3/(m.sup.2.times.min), as determined by EDANA method 140-1-99
(125 Pa, 38.3 cm.sup.2). The supporting sheet (16) may
alternatively have a lower air-permeability, e.g. being
non-air-permeable, to for example be better detained on a moving
surface comprising vacuum.
In some executions, the supporting sheet (16) is a nonwoven
laminate material, a nonwoven laminate web, for example of the SMS
or SMMS type.
In order to form easily said undulations, the supporting sheet (16)
may have a basis weight that is less than 60 gsm, or for example
than 50 gsm, for example from 5 gsm to 40 gsm, or to 30 gsm.
The supporting sheet (16) may have a CD-extensibility or a
MD-extensibility.
In one of the embodiment herein, the supporting sheet (16) has
undulations that fold (undulate) into said first and second
channels (26), and optionally in to said further channels, of part
thereof. For example the undulations may extend over about the full
longitudinal dimension of the channel; they may for example extend
to complete average height of the absorbent layer (17)/channel, or
for example only up to 75% thereof, or up to 50% of the average
height of the absorbent layer (17)/channel. This aids
immobilization of the absorbent material (50) adjacent said
channels (26) and said channels (26) of said layers.
The undulations may be adhered with said one or more adhesive
material, e.g. said second adhesive material, to said walls of said
channels (26). The supporting sheet (16) may alternatively, or in
addition, be adhered in said channels (26) to said further
material, e.g. second supporting sheet (16), describe herein above,
e.g. with said first and/or second adhesive.
The absorbent structure (13) may comprise one or more adhesive
materials. In some embodiments, it comprises a first adhesive
material and/or a second adhesive material, as described above, and
in the manner described above.
The absorbent core herein may comprise a further second absorbent
structure that may comprise one or more adhesive materials; the
following equally applies thereto.
Any suitable adhesive can be used for this, for example so-called
hotmelt adhesives used. For example, a sprayable hot melt
adhesives, such as H.B. Fuller Co. (St. Paul, Minn.) Product No.
HL-1620-B, can be used.
The adhesive materials may not only help in immobilizing the
absorbent material on the supporting sheet but it may also help in
maintaining the integrity of the channels in the absorbent
structure absorbent core during storage and/or during use of the
disposable article. The adhesive material may help to avoid that a
significant amount of absorbent material migrates into the
channels. Furthermore, when the adhesive material is applied in the
channels or on the supporting sheet portions coinciding with the
channels it may thereby help to adhere the supporting sheet of the
absorbent structure to said walls, and/or to a further material, as
will be described in further details below.
In some embodiments, the first adhesive (40) and/or the second
adhesive (60) may be a thermoplastic adhesive material.
In some embodiments, the first adhesive (40) may be applied as
fibers, forming a fibrous network that immobilizes the absorbent
material on the supporting sheet. The thermoplastic adhesive fibers
may be partially in contact with the supporting sheet of the
absorbent structure; if applied also in the channels, it (further)
anchors the absorbent layer to the supporting sheet.
The thermoplastic adhesive material may for example allow for such
swelling, without breaking and without imparting too many
compressive forces, which would restrain the absorbent polymer
particles from swelling. Thermoplastic adhesive materials (40; 60)
suitable for use in the present disclosure includes hot melt
adhesives comprising at least a thermoplastic polymer in
combination with a plasticizer and other thermoplastic diluents
such as tackifying resins and additives such as antioxidants.
Exemplary suitable hot melt adhesive materials (40; 60) are
described in EP 1447067 A2. In some embodiments, the thermoplastic
polymer has a molecular weight (Mw) of more than 10,000 and a glass
transition temperature (Tg) below room temperature or -6.degree.
C.>Tg<16.degree. C. In certain embodiments, the
concentrations of the polymer in a hot melt are in the range of
about 20 to about 40% by weight. In certain embodiments,
thermoplastic polymers may be water insensitive. Exemplary polymers
are (styrenic) block copolymers including A-B-A triblock
structures, A-B diblock structures and (A-B)n radial block
copolymer structures wherein the A blocks are non-elastomeric
polymer blocks, typically comprising polystyrene, and the B blocks
are unsaturated conjugated diene or (partly) hydrogenated versions
of such. The B block is typically isoprene, butadiene,
ethylene/butylene (hydrogenated butadiene), ethylene/propylene
(hydrogenated isoprene), and mixtures thereof.
Other suitable thermoplastic polymers that may be employed are
metallocene polyolefins, which are ethylene polymers prepared using
single-site or metallocene catalysts. Therein, at least one
comonomer can be polymerized with ethylene to make a copolymer,
terpolymer or higher order polymer. Also applicable are amorphous
polyolefins or amorphous polyalphaolefins (APAO) which are
homopolymers, copolymers or terpolymers of C2 to C8 alpha
olefins.
The thermoplastic adhesive material, typically a hot-melt adhesive
material, is generally present in the form of fibers, i.e. the hot
melt adhesive can be fiberized. In some embodiments, the
thermoplastic adhesive material forms a fibrous network over the
absorbent polymer particles. Typically, the fibers can have an
average thickness from about 1 .mu.m to about 100 .mu.m, or from
about 25 .mu.m to about 75 .mu.m, and an average length from about
5 mm to about 50 cm. In particular the layer of hot melt adhesive
material can be provided such as to comprise a net-like structure.
In certain embodiments the thermoplastic adhesive material is
applied at an amount of from 0.5 to 30 g/m.sup.2, or from 1 to 15
g/m.sup.2, or from 1 and 10 g/m.sup.2 or even from 1.5 and 5
g/m.sup.2 per supporting sheet (16).
A typical parameter for an adhesive suitable for use in the present
disclosure can be a loss angle tan Delta at 60.degree. C. of below
the value of 1, or below the value of 0.5. The loss angle tan Delta
at 60.degree. C. is correlated with the liquid character of an
adhesive at elevated ambient temperatures. The lower tan Delta, the
more an adhesive behaves like a solid rather than a liquid, i.e.
the lower its tendency to flow or to migrate and the lower the
tendency of an adhesive superstructure as described herein to
deteriorate or even to collapse over time. This value is hence
particularly important if the absorbent article is used in a hot
climate.
It may be beneficial, e.g. for process reasons and/or performance
reasons, that the thermoplastic adhesive material has a viscosity
of between 800 and 4000 mPas, or from 1000 mPas or 1200 mPas or
from 1600 mPas to 3200 mPas or to 3000 mPas or to 2800 mPas or to
2500 mPas, at 175.degree. C., as measurable by ASTM D3236-88, using
spindle 27, 20 pmp, 20 minutes preheating at the temperature, and
stirring for 10 min.
The thermoplastic adhesive material may have a softening point of
between 60.degree. C. and 150.degree. C., or between 75.degree. C.
and 135.degree. C., or between 90.degree. C. and 130.degree. C., or
between 100.degree. C. and 115.degree. C., as can be determined
with ASTM E28-99 (Herzog method; using glycerine).
In one embodiment herein, the thermoplastic adhesive component may
be hydrophilic, having a contact angle of less than 90.degree., or
less than 80.degree. or less than 75.degree. or less than
70.degree., as measurable with ASTM D 5725-99.
The absorbent articles of the present invention may comprise
signals that communicate to the consumer the functionality and
benefits of the absorbent core channels. Non-limiting examples of
such signals may include printed adhesive layers, backsheet
graphics, embossing of the topsheet and/or acquisition layer, and
combinations thereof.
One type of signal that may be used to communicate the existence
and the benefits of the channels is a printed adhesive layer. In
some embodiments, an article with channels in the core may have a
layer of an adhesive that is applied in a pattern that connotes the
absorbency and other benefits of the channels. This adhesive layer
may be applied to a substrate, such as a supporting layer, in some
embodiments an acquisition layer, that may be positioned between a
topsheet and the absorbent core with channels. In some embodiments,
the layer of printed adhesive may be visible through the
topsheet.
In some embodiments, a fluid, such as an adhesive, may be applied
or printed onto an advancing substrate. The fluid application
apparatus may include a slot die applicator and a substrate
carrier. The slot die applicator may include a slot opening, a
first lip, and a second lip, the slot opening located between the
first lip and the second lip. And the substrate carrier may include
one or more pattern elements and may be adapted to advance the
substrate past the slot die applicator as the slot die applicator
discharges adhesive onto the substrate. In operation, when the
first surface of the substrate is disposed on the substrate
carrier, the substrate carrier advances the second surface of the
substrate past the slot opening of the slot die applicator. In
turn, the substrate is intermittently compressed between the slot
die applicator and the pattern surface of the pattern element. As
the substrate is intermittently compressed, adhesive discharged
from the slot die applicator is applied onto the second surface of
the advancing substrate in an area having a shape that is
substantially the same as a shape defined by the pattern surface.
In some embodiments, the adhesive may be a different color than the
substrate. The adhesive may comprise pigments or dyes. Other
methods and apparatuses involved for the application of adhesives
in pre-determined patterns to an advancing substrate are disclosed
in U.S. Pat. No. 8,186,296. In some embodiments, the fluid printed
on the substrate may be an ink without an adhesive.
The term "pattern" as used herein means a decorative or distinctive
design, not necessarily repeating or imitative, including but not
limited to the following: marbled, check, mottled, veined,
clustered, geometric, spotted, helical, swirl, arrayed, variegated,
textured, spiral, cycle, contoured, laced, tessellated, starburst,
lobed, lightning, blocks, textured, pleated, cupped, concave,
convex, braided, tapered, and combinations thereof. The curves
lines of the printed adhesive layer may signal to the consumer one
or more benefits of the channels. For example, the channels may act
as a conduit, distributing fluid to a more comfortable place, while
the printed adhesive layer, visible to the caregiver through the
topsheet, may signal or communicate the fluid distribution and
comfort that the article can provide.
As discussed above, the absorbent structure of the present
invention typically comprises one or more further materials, such
as a further material layer, to cover the absorbent layer. This
layer may comprise an adhesive, for example on the surface that is
to contact the absorbent layer of the absorbent structure. Thus,
the further material may comprise on the surface to be placed
adjacent said absorbent layer of the absorbent structure, an
adhesive material. In some embodiments, the further material layer
may be an acquisition material layer that may have the adhesive
printed onto it to form a patterned appearance. Thus, the adhesive
is printed onto the surface of the acquisition layer that is
adjacent to the absorbent core. In addition to an absorbent core
with channels and a printed adhesive layer printed onto the surface
of the acquisition layer adjacent to the absorbent core, the
article may also comprise a topsheet, wherein the printed adhesive
layer is visible through the topsheet. In some embodiments, the
printing (ink or an adhesive with ink) may be on the topsheet
itself, and where ink is the substance being printed, the printing
may be performed using digital printing.
In some embodiments, the absorbent article may comprise graphics
printed onto the backsheet. As the absorbent core is loaded with
fluid, the absorbent material will expand in particular towards the
backsheet, while the channels which do not comprise absorbent
material will not expand. This difference may be used, as the
channels will become more perceptible through the backsheet as
fluid is absorbed as they may form depressions. These depressions
will become more pronounced as the absorbent article absorbs the
fluid.
The depth of these depressions formed by the channels on the
backsheet side will be proportional to the amount of fluid
absorbed, and the inventors have found that that the visual
appearance to the caregiver may be improved by providing a
backsheet printing which matches or at least indicates the region
of the channels to the caregiver. Thus the backsheet printing may
comprise a line or a curve which substantially matches the shape
and/or position of the channels.
Backsheet graphics may similarly signal to the caregiver the
attributes of the channels. In some embodiments, the only visual
signal of the channels may be the backsheet printing. In some
embodiments, the backsheet printing may be curves, lines, or other
patterns that approximate the shape and contours of the channels.
In some embodiments, the article may comprise both a printed
adhesive layer and backsheet graphics, the combination of which
work together or separately to accentuate certain channel
aspects.
The relative lengths of any of the lines above may be expressed as
ratios, and may be exact, or may be expressed with a tolerance of
plus or minus 2%, 3%, 4%, 5%, 7%, 10%, 12%, 15%, 17%, 20%, 22%,
25%, 27%, 30%, alone or in combination with other ratios of
lengths, and the length may be rounded to the nearest whole number
or multiple of 5, after the percent of tolerance is applied.
Further, in some embodiments, the graphics visually signaling the
inner channels will not extend beyond the area of the outer
channels themselves, and/or the area where the absorbent core is
present, and in some embodiments, the graphics visually signaling
the outer channels will not extend beyond the area of the outer
channels themselves, and/or the area where the absorbent core is
present, and in some embodiments, the graphics visually signaling
the inner and outer channels will not extend beyond the area of the
inner and outer channels themselves, and/or the area where the
absorbent core is present.
In addition, the article may comprise other or additional visual
cues that signal the absorbent core channels, such as, for example,
embossing. Embossing may be done on the topsheet or on the
absorbent core, or, in some embodiments, there may be multi-layer
embossing of both the topsheet and the absorbent core. For example,
thermal embossing may be done over the channels (where there is no
superabsorbent polymer) at a small gap setting to enhance the
visual presence. Any embossing may be done alone or in combination
with printing to help signal the absorbent core channels. Further,
any embossing may be done to the topsheet, core, or both, on-line
(during assembly of the absorbent article's component parts) or
prior to such assembly, e.g. at the site where a supplier of
component parts makes the component part itself.
In some embodiments, the printed adhesive layer or the backsheet
printing may be a pattern that covers the majority or even all of
the absorbent core. In other embodiments, the printed adhesive
layer or backsheet printing may be printed only in discrete areas.
For example, in some embodiments, the printed adhesive layer or
backsheet printing may be printed so as to not overlap or intersect
with the absorbent core channels. The term "overlap" as used herein
means to cover over a part of, or to have an area in common. The
term "intersect" as used herein means items that cut across or
through each other, or that narrow and merge.
In order to ensure that absorbent article components (including
graphic absorbent article components) are properly oriented when
attached to other absorbent article components, registration may be
used. Registration may include using a system to detect a location
on an absorbent article component and to compare the location
against a set point (which may be an operator desired or machine
set location). The system may adjust placement of the absorbent
article component in accordance with said comparison. For example,
the location of absorbent core channels and a printed adhesive
layer may be detected and a repeat length of the printed adhesive
layer may be altered via a length control system (described in U.S.
Pat. Nos. 6,444,064 and 6,955,733). Alternatively, a system may be
used to detect and control the longitudinal or machine direction
position of a component relative to a desired position on the
absorbent article wherein the position at which subsequent
occurrences of a first component is attached to a second component
is altered to ensure the first component is in the desired
location. Such can be performed based on multiple detections and
the use of an averaging position, deviation from the desired
position, or by detecting less frequently than every occurrence.
Additionally, a system may detect a first location on a first
absorbent article component and a second location on a second
absorbent article component, where the first and second locations
may be compared relative to each other and against a set point or
desired offset position. The system may adjust placement of the
first and/or second absorbent article components in accordance with
said comparison. Combinations of detection methods may be used.
In some embodiments, registration may be used to optimize the
visual impression of the printing and the absorbent core
channels.
In some embodiments, any printing, whether a printed adhesive
layer, a backsheet graphic, or some combination, may match, or
substantially match the shape or contour of the absorbent core
channels. In some embodiments, the printing will not necessarily
match or overlap or correlate with the shape or contour of the
absorbent core channels, but will otherwise communicate or signal
to the consumer the existence and/or benefits of the channels.
The absorbent structure (13) or absorbent core (7) herein may be
useful in an absorbent article, such as described above, and in
particular in a diaper (1), including fastenable diapers (1) and
(refastenable) training pants, for infants or for adults, or in an
absorbent pad, such as a sanitary napkin or adult incontinence
undergarment pad.
The article may comprise, in addition to an absorbent structure
(13) or absorbent core (7) as described herein, a topsheet and
backsheet, and for example one or more side flaps or cuffs. The
topsheet or cuffs or side flaps may comprise a skin care
composition or lotion or powder, known in the art, panels,
including those described in U.S. Pat. Nos. 5,607,760; 5,609,587;
5,635,191; 5,643,588.
Articles herein comprise a topsheet, facing the wearer in use, for
example a nonwoven sheet, and/or an apertured sheet, including
apertured formed films, as known in the art, and a backsheet.
The backsheet may be liquid impervious, as known in the art. In
some embodiments, the liquid impervious backsheet comprises a thin
plastic film such as a thermoplastic film having a thickness of
about 0.01 mm to about 0.05 mm. Suitable backsheet materials
comprise typically breathable material, which permit vapors to
escape from the diaper (1) while still preventing exudates from
passing through the backsheet. Suitable backsheet films include
those manufactured by Tredegar Industries Inc. of Terre Haute, Ind.
and sold under the trade names X15306, X10962 and X10964.
The backsheet, or any portion thereof, may be elastically
extendable in one or more directions. The backsheet may be attached
or joined to a topsheet, the absorbent structure/core, or any other
element of the diaper (1) by any attachment means known in the
art.
Diapers herein may comprise leg cuffs and/or barrier cuffs; the
article then typically has a pair of opposing side flaps and/or leg
and/or barrier cuffs, each of a pair being positioned adjacent one
longitudinal side of the absorbent structure/core, and extending
longitudinally along said structure/core, and typically being
mirror images of one another in the longitudinal-axis of the
article; if leg cuffs and barrier cuffs are present, then each leg
cuffs is typically positioned outwardly from a barrier cuff. The
cuffs may be extending longitudinally along at least 70% of the
length of the article. The cuffs may have a free longitudinal edge
that can be positioned out of the X-Y plane
(longitudinal/transverse directions) of the article, i.e. in
z-direction. The side flaps or cuffs of a pair may be mirror images
of one another in the longitudinal axis of the article. The cuffs
may comprise elastic material.
The diapers herein may comprise a waistband, or for example a front
waistband and back waist band, which may comprise elastic
material.
The diaper (1) may comprise side panels, or so-called ear panels.
The diaper (1) may comprise fastening means, to fasten the front
and back, e.g. the front and back waistband. Fastening systems may
comprise fastening tabs and landing zones, wherein the fastening
tabs are attached or joined to the back region of the diaper (1)
and the landing zones are part of the front region of the diaper
(1).
The absorbent structure (13) may be combined with, and the
absorbent core (7) or diaper (1) may comprise, an acquisition layer
and/or acquisition material layer, or system thereof this may
comprise chemically cross-linked cellulosic fibers. Such
cross-linked cellulosic fibers may have desirable absorbency
properties. Exemplary chemically cross-linked cellulosic fibers are
disclosed in U.S. Pat. No. 5,137,537. In certain embodiments, the
chemically cross-linked cellulosic fibers are cross-linked with
between about 0.5 mole % and about 10.0 mole % of a C.sub.2 to
C.sub.9 polycarboxylic cross-linking agent or between about 1.5
mole % and about 6.0 mole % of a C.sub.2 to C.sub.9 polycarboxylic
cross-linking agent based on glucose unit. Citric acid is an
exemplary cross-linking agent. In other embodiments, polyacrylic
acids may be used. Further, according to certain embodiments, the
cross-linked cellulosic fibers have a water retention value of
about 25 to about 60, or about 28 to about 50, or about 30 to about
45. A method for determining water retention value is disclosed in
U.S. Pat. No. 5,137,537. According to certain embodiments, the
cross-linked cellulosic fibers may be crimped, twisted, or curled,
or a combination thereof including crimped, twisted, and
curled.
In a certain embodiment, one or both of the upper and lower
acquisition layers may comprise a non-woven, which may be
hydrophilic. Further, according to a certain embodiment, one or
both of the upper and lower acquisition layers may comprise the
chemically cross-linked cellulosic fibers, which may or may not
form part of a nonwoven material. According to an exemplary
embodiment, the upper acquisition layer may comprise a nonwoven,
without the cross-linked cellulosic fibers, and the lower
acquisition layer may comprise the chemically cross-linked
cellulosic fibers. Further, according to an embodiment, the lower
acquisition layer may comprise the chemically cross-linked
cellulosic fibers mixed with other fibers such as natural or
synthetic polymeric fibers. According to exemplary embodiments,
such other natural or synthetic polymeric fibers may include high
surface area fibers, thermoplastic binding fibers, polyethylene
fibers, polypropylene fibers, PET fibers, rayon fibers, lyocell
fibers, and mixtures thereof. Suitable non-woven materials for the
upper and lower acquisition layers include, but are not limited to
SMS material, comprising a spunbonded, a melt-blown and a further
spunbonded layer. In certain embodiments, permanently hydrophilic
non-wovens, and in particular, nonwovens with durably hydrophilic
coatings are desirable. Another suitable embodiment comprises a
SMMS-structure. In certain embodiments, the non-wovens are
porous.
The diaper (1) may include a sub-layer disposed between the
topsheet and the absorbent structure (13)/absorbent core (7),
capable of accepting, and distributing and/or immobilizing bodily
exudates. Suitable sublayers include acquisition layers, surge
layers and or fecal material storage layers, as known in the art.
Suitable materials for use as the sub-layer may include large cell
open foams, macro-porous compression resistant nonwoven highlofts,
large size particulate forms of open and closed cell foams (macro
and/or microporous), highloft non-wovens, polyolefin, polystyrene,
polyurethane foams or particles, structures comprising a
multiplicity of vertically oriented, looped, strands of fibers, or
apertured formed films, as described above with respect to the
genital coversheet. (As used herein, the term "microporous" refers
to materials that are capable of transporting fluids by capillary
action, but having a mean pore size of more than 50 microns. The
term "macroporous" refers to materials having pores too large to
effect capillary transport of fluid, generally having pores greater
than about 0.5 mm (mean) in diameter and more specifically, having
pores greater than about 1.0 mm (mean) in diameter, but typically
less than 10 mm or even less than 6 mm (mean).
Processes for assembling the absorbent article or diaper (1)
include conventional techniques known in the art for constructing
and configuring disposable absorbent articles. For example, the
backsheet and/or the topsheet can be joined to the absorbent
structure/core or to each other by a uniform continuous layer of
adhesive, a patterned layer of adhesive, or an array of separate
lines, spirals, or spots of adhesive. Adhesives which have been
found to be satisfactory are manufactured by H. B. Fuller Company
of St. Paul, Minn. under the designation HL-1258 or H-2031. While
the topsheet, the backsheet, and the absorbent structure (13)/core
may be assembled in a variety of well-known configurations, diaper
(1) configurations are described generally in U.S. Pat. No.
5,554,145 entitled "Absorbent Article With Multiple Zone Structural
Elastic-Like Film Web Extensible Waist Feature" issued to Roe et
al. on Sep. 10, 1996; U.S. Pat. No. 5,569,234 entitled "Disposable
Pull-On Pant" issued to Buell et al. on Oct. 29, 1996; and U.S.
Pat. No. 6,004,306 entitled "Absorbent Article With
Multi-Directional Extensible Side Panels" issued to Robles et al.
on Dec. 21, 1999.
As discussed above, there is a need for providing absorbent
articles with absorbent cores that comprise channels and printed
signals that communicate the channels. A further need exists in
that the particular combinations of channels and printed signals
can be optimized to improve such communication.
The inventors have contemplated providing signals comprising two
elements: an underlay (as shown in FIG. 4a) and a pattern fill (as
shown in FIG. 4b). The signals themselves may comprise adhesive,
ink, or both, or blends of adhesive and ink.
However, there are difficulties in attempting to find combinations
of underlays and pattern fills that would provide sufficient visual
appeal to caregivers with the technical and cost feasibilities of
mass-producing absorbent articles. The distance between the
channels' innermost contoured lines D may be important in providing
absorbent cores that exhibit excellent process capability,
technical product performance, and have a successful consumer
communication. If the distance between the contoured lines D is too
small, the process capability may be negatively impacted by
equipment wear and material wrapping. Further, product performance
may be negatively impacted by slower acquisition speeds. If the
distance between the contoured lines D is too large, the process
capability may be negatively impacted by not having enough contact
to remove adhesive, thereby causing contamination. Further,
consumer communication may be negatively impacted by a pattern that
is not consistently visible and a low color intensity.
Further, the adhesive coverage area may be important in providing
absorbent cores that exhibit excellent process capability,
technical product performance, and have a successful consumer
communication. If the adhesive coverage area is too small, the
process capability may be negatively impacted by not having enough
glue coverage to maintain control of the patch in process. Further,
consumer communication may be negatively impacted by not having
enough adhesive pattern to deliver a consumer message. If the
adhesive coverage area is too great, the process capability may be
negatively impacted by having too much adhesive to deliver the
process consistently. Further, consumer communication may be
negatively impacted by leading to a lack of absorbency
signaling.
Combinations such as those shown in FIGS. 5a and 5b, are found to
be visually successful but technically not feasible. For example,
these designs may be perceived as providing too much white space in
between the contoured lines, e.g. more than 25 mm, which is
difficult to achieve from a manufacturing standpoint. Overall this
design may not provide enough adhesive to hold the absorbent
article components together, as pattern coverage with the adhesive
is less than 15%, and may also be difficult to manufacture due to
centerline difficulties.
Combinations such as those shown in FIGS. 6a and 6b, are found to
be visually successful and technically feasible. For example, these
designs may be perceived as balancing the placement and amount of
adhesive which allows for sufficient bonding of absorbent article
layer components to each other, and also allows for good fluid
handling, and process-ability. These designs may be perceived as
providing a suitable amount of space in between the contoured
lines, e.g. from 15 mm to 25 mm, which is able to be achieved from
a manufacturing standpoint. Overall this design may suitably
provide enough adhesive to hold the absorbent article components
together, as pattern coverage with the adhesive is from 15% to 30%,
and may be suitable to manufacture due to centerline being
established, e.g. for base conditions to deliver at about 150N of
force (nozzle to substrate+plate).
Combinations such as those shown in FIGS. 7a and 7b, are found to
be visually unsuccessful and technically not feasible. For example,
these designs may be perceived as providing not enough contrast
between the underlay and the fill pattern. Overall this design may
provide too much adhesive for proper fluid handling, as pattern
coverage with the adhesive is more than 30%, and may also be
difficult to manufacture due to centerline difficulties.
As such, in some embodiments of the present invention, the distance
between the innermost pair of contoured lines is from about 10 mm
to about 30 mm, from about 15 mm to about 25 mm, from about 18 mm
to about 22 mm, less than about 30 mm, less than about 25 mm, more
than about 10 mm, more than about 15 mm.
As such, in some embodiments of the present invention, the amount
of adhesive comprising the printed adhesive layer is such that the
pattern coverage with the adhesive is from about 10% to about 35%,
from about 15% to about 30%, from about 20% to about 25%, less than
about 35%, less than about 30%, more than about 10%, more than
about 15%.
The dimensions and values disclosed herein are not to be understood
as being strictly limited to the exact numerical values recited.
Instead, unless otherwise specified, each such dimension is
intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
Every document cited herein, including any cross referenced or
related patent or application, is hereby incorporated herein by
reference in its entirety unless expressly excluded or otherwise
limited. The citation of any document is not an admission that it
is prior art with respect to any invention disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
invention. Further, to the extent that any meaning or definition of
a term in this document conflicts with any meaning or definition of
the same term in a document incorporated by reference, the meaning
or definition assigned to that term in this document shall
govern.
While particular embodiments of the present invention have been
illustrated and described, it would be obvious to those skilled in
the art that various other changes and modifications can be made
without departing from the spirit and scope of the invention. It is
therefore intended to cover in the appended claims all such changes
and modifications that are within the scope of this invention.
* * * * *